Filtration media incorporating nanoparticles and large linear density fibers

Abstract

Filter media and filters, such as air filters, face masks, gas turbine and compressor air intake filters, panel filters and the like, are provided that include high linear density fibers and nanoparticles dispersed throughout at least a portion of the filter media. A filter includes a filter media comprising a substrate of fibers having a linear density of greater than about 3 denier, and nanoparticles disposed within the substrate. The larger linear density fibers provide more open space or pores within the filter media, allowing for a greater density of nanoparticles to be dispersed therein. This improves the overall efficiency of the filter. The three-dimensional distribution of nanoparticles within the filter also provides resistance against complete blockage of a particular portion of the filter, thereby reducing the overall pressure drop across the filter.

What is claimed is: 
     
         1 . A filter comprising:
 a filter media comprising a nonwoven substrate of fibers having a linear density of greater than about 3 denier; and   nanoparticles disposed within the nonwoven substrate, wherein the nanoparticles have at least one dimension less than 1 micron.   
     
     
         2 . The filter of  claim 1 , wherein the fibers have a linear density of at least 5 denier. 
     
     
         3 . The filter of  claim 1 , wherein the fibers have a linear density of at least 8 denier. 
     
     
         4 . The filter of  claim 1 , wherein the nonwoven fiber substrate has a thickness from a first surface to a second surface, wherein the nanoparticles are disposed within the nonwoven fiber substrate in at least 25% of the thickness from the first surface to the second surface. 
     
     
         5 . The filter of  claim 1 , wherein at least some of the nanoparticles are disposed within the nonwoven fiber substrate from the first surface to the second surface. 
     
     
         6 . The filter of  claim 1 , wherein the nanoparticles form a gradient within the nonwoven fiber substrate such that a density of the nanoparticles decreases from the first surface to the second surface. 
     
     
         7 . The filter of  claim 1 , wherein the nanoparticles are substantially uniformly dispersed throughout the fibrous material. 
     
     
         8 . The filter of  claim 1 , wherein the nanoparticles are generated within a gas and dispersed through the first surface of the fibrous material. 
     
     
         9 . The filter of  claim 1 , wherein the filter has a MERV rating greater than about 10 and a pressure drop less than about 0.5 inches of water. 
     
     
         10 . The filter of  claim 2 , wherein the filter has a MERV rating of about 13 and the pressure drop is equal to or less than about 0.31 inches of water. 
     
     
         11 . The filter of  claim 2 , wherein the fibers comprises glass. 
     
     
         12 . The filter of  claim 13 , wherein the filter has a MERV rating of at least 13 and a pressure drop of 0.24 or less inches of water. 
     
     
         13 . A filter comprising:
 a first layer comprising a nonwoven substrate of fibers having a linear density of greater than about 3 denier and nanoparticles disposed within the nonwoven substrate, wherein the nanoparticles have at least one dimension less than 1 micron; and   a second layer comprising a nonwoven substrate of fibers bonded to the first layer.   
     
     
         14 . The filter of  claim 13 , wherein the fibers in the first layer have a linear density of at least 5 denier. 
     
     
         15 . The filter of  claim 13 , wherein the fibers in the first layer have a linear density of at least 6 denier. 
     
     
         16 . The filter of  claim 13 , wherein the fibers in the first layer have a linear density of at least 8 denier. 
     
     
         17 . The filter of  claim 13 , wherein the fibers in the second layer have a linear density of 3 denier or less. 
     
     
         18 . The filter of  claim 13 , wherein the fibers in the first layer have a linear density of about 7 Denier and the fibers in the second layer have a linear density of about 7 Denier. 
     
     
         19 . The filter of  claim 18 , wherein the filter has a MERV rating of at least 13 and a pressure drop of 0.31 or less inches of water. 
     
     
         20 . The filter of  claim 13 , further comprising nanoparticles disposed within the second layer, wherein the nanoparticles have at least one dimension less than 1 micron.